Upgraded / Redesigned FSI Cam Follower

1/22/12 Just a quick warning: this company may not be as legitimate as the VW community thinks. Several Mazda websites do not have fond memories of this particular company. I’ll have to find more information…Stay away for now.

For the past few months, the company HPFP Upgrade has been working on creating a cam follower that is more durable than the oem piece. Testing is now practically complete. I’m guessing that they are in production right now with a probable February release. HPFP Upgrade is a relatively new (to me) company that focuses on the fueling system for various direction injection cars.

There’s been a good deal of anticipation regarding this product. Any product that can help with the FSI’s follower problem is welcome. The company states that it has achieved an increase in durability through the use of hard chroming. By creating a surface with less friction, there is less wear between the follower and cam. Testing supposedly confirms their claims. In addition to the new surface material, the oil flow holes were relocated to the sides. Information is limited right now as the company has yet to officially release the product.

Early Production Photos - Note the revised oiling hole locations

Of course, the product is untested by the mass public and details such as warranty have yet to be hashed out. There are still unanswered questions. How will the relocation of the oil holes affect things and how durable will the follower and hard chrome finish really be in real life application? HPFP Upgrade asserts that the the new finish is much tougher than the OEM DLC coated follower and slicker as well. They also say that the relocation of the oiling holes also has nothing but positive effects, although their reasoning is yet to be seen. The company seems to have done its homework, field testing a few units with favorable results. So far better than another company that just made the follower thicker and omitted the DLC coating…*cough*kmd*cough*. The design is superficially similar to followers used by Mazda.

I’m following this product quite closely and will probably try it out when it does finally get released.

Here’s a thread on the MKV forum with a few details but it unfortunately turns into a flame war in a page or so. Upgraded FSI Cam Follower

If you do end up getting this in a month or two, let everyone know what you think of it in the comments.

Camshaft and Cam Follower Warranty Extension

 

In addition to the pcv and intake manifold motor, Volkswagen also extended the warranty on the camshaft, cam follower and high pressure fuel pump to 120,000 miles or 10 years. As before, they will reimburse any out of pocket expenses related to failure of any of these components provided you have proof of payment and repair. Keep in mind this does not cover replacing followers, only components that have failed or have insufficient hardening. Look through the following letter and see what applies to you.For more information, check out my other posts:Cam Follower Camshaft and Cam Follower Warranty Extension

Camshaft and Cam Follower Warranty Extension

November – Quick Update

Sorry it’s been so long since I’ve written a post, things have been a little quiet on the MKV front. My car is in a place where I like everything on it so I’ve been leaving it alone. The platform is getting older but that doesn’t mean new things aren’t being developed! There are a few particular developments that I want to talk about regarding fueling and cam follower improvements. One company has decided to research and produce a replacement follower that should all but eliminate excessive wear from this part. It has not been released yet but is due to show up in December. I’ll have more information as it becomes available.

Cam Follower 45,000 Mile Checkup

Second Cam Follower, around 45,000 miles on it. The car has almost 100,000 miles now.

I pulled the cam follower to check how it was doing.  It’s been quite a while since I last checked.  I’m estimating the total mileage on this to be about 45,000 miles.  This is only the second cam follower this car has seen.  Nonetheless, the wear is excellent and I’m popping this one back in.  I’ll check back in 10,000 miles, which this should easily last.  The DLC coat is still not completely worn through in the center.

Cam Follower Warranty Extension

Good news everybody! VW of America has decided to extend the cam follower, high pressure fuel pump, and intake camshaft warranty to 120,000 miles or 10 years. I received a letter in the mail. It took a while but VW finally did the right thing.

I’ll load the letter once I get it scanned. documents added below

Here are a few links related to the cam follower problem:

Cam Follower 1

Cam Follower 2

Cam Follower 3

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Cam Follower and Oil Change Article

Since the MKV generation is starting to hit higher mileages, the cam follower wear problem is starting to pop up more often.  I see it being posted more in the forums.  Usually it’s by people who just bought the car used or simply were unaware of the issue.  That really sucks.  Anyway check out the page under the maintenance drop down or click this link.  Cam followers and Oil changes – Warning

Heres another article: Cam Follower Troubleshooting

Edit:  I see a couple of searches for “revised follower”  - Sorry there is none, this is what we have to deal with and the solution is constant awareness-

I borrowed this picture to show the possible damage.  If the original owner wants it removed, please tell me.

Cam Follower – Progress Report

This current follower has 30,000 miles on it, 15~20,000 of it on APR Stage I.  I changed out my first one at around 57,000 miles.  This new one still has not developed any appreciable wear.  The DLC coating is still there, unworn for all intents and purposes.

There has to be a rhyme and reason to all this.  Is it really just people using poor oil?  Not breaking the car in properly?  Too early for the first oil change?  Manufacturing flaws?

While there was improper cam hardening with the A cams, the B cams supposedly remedied that problem and there are still reports of failure.  My car does not have any accelerated wear.  Other cars chew them up in as little as 10,000 miles.

My advice would be to check at least every other oil change until you’ve established the rate of wear.  Then you can increase your intervals.  Keep in mind that wear is also accelerated as the cam follower wears down.

Links to more information:

Cam follower check

Maintenance Page

Troubleshooting

Cam Follower Troubleshooting

There still seems to be a good number of people who are unaware of the cam follower problems.  Not all cars have the problem, and some may never have it.  BUT it will kill your wallet if you find out yours is on the edge of dying and you are out of warranty.

There is no set of factors that directly contributes to the wear.  If you have the A cam, there is a TSB out to replace your cam with the properly hardened B cam.  VW will only replace the cam if the car is throwing codes or a check engine light or if they physically see the damage.  The problem can still occur but having the B cam reduces the risks.  I have had no problems and as far as the internet world is concerned, much of Europe seems to be just fine.  The number of factors affecting the rate of follower wear is just enormous.  It could be oil standards, fuel quality, driving habits, maintenance, and so on.  The design has been remedied on the newer TSI engines with a roller follower.  This design should have been used in the first place instead of the flat tappet style used on the FSI.

Here are a few links to check out:

Cam follower check

Maintenance Page

A smooth unblemished cam

The most common symptom of a cam follower in trouble is a fuel cut.  This feels like someone just took the gas pedal out from under you.  It does NOT feel good.  This doesn’t always come up with check light or code.  Which leads us to the most obvious signs. These codes may come up when scanned.

-P0087 Fuel Rail / System Pressure – Too Low
-P1093 Fuel Trim 2, Bank 1 Malfunction
-P2293 Fuel Pressure Regulator 2 Performance

If these come up, check your follower.  These can be symptomatic of other problems as well so don’t panic yet.  Check  the thrust sensor on the high pressure fuel pump.  Your low pressure fuel pump could also be on its way out.  These are all much cheaper problems than the cam situation.  Best case scenario is that the ecu just glitched.  Worst case, destroyed cam, follower and fuel pump. If you have never checked your cam follower and you have any kind of mileage, do so now.  Don’t count on the dealer to check for you.  It won’t destroy itself in 5000 miles but check every other oil change.  If wear looks minimal every time you check, you can lessen the intervals.

The picture on the left shows a follower with normal wear patterns.  You can replace it if you wish but it can probably go a few more miles.  The part number is 06D 109 309 C. 1stvwparts has excellent pricing.  Note that the edges still have some of the DLC coating on it.  If yours does not, then that is absolutely time to change.  I haven’t seen too many that look so clean.   If your foll0wer looks like the picture on the right, sob quietly and then proceed to the dealership, if under warranty, and hope for the best.  Or if not under warranty, prepare to feel a world of hurt.  It’s going to be pricey.  Replacement of the cam is recommended to be done at a shop or qualified service center.  It is not really a job for the weekend mechanic as it needs specialized tools.

~57000 miles

~57000 miles

destroyed

Unknown mileage, center punched out

Cam Follower – 66,000 Mile Update

About 10,000 miles on follower

About 10,000 miles on follower

I’ve put about 10,000 miles on this new follower.   The picture doesn’t show too well, but you can barely make out some wear in the center.  I wasn’t expecting it to look that good.  That’s great news for me.  Other people haven’t been so lucky.  Oil has been Lubromoly 5w-40 the entire time.  Now that I’m chipped, we’ll have to wait and see whether that affects anything.

Cam Follower

~57000 miles

The 2.0 T FSI has had a couple of issues with the high pressure fuel pump failing.  The problems can mostly be traced back to either a worn cam follower, worn cam or both.  The issue seems to be hit or miss with the BPY engine.  This follower here has approximately 57,000 miles on it and has no abnormal wear.  Other cars have have much higher wear rates at lower mileages.

There are two cam revisions, A and B. The A cams supposedly received incorrect hardening. Having the B cam reduces the risk of wear, but having the revised cam does not make you immune to the issue either.  Volkswagen has issued a TSB for it and if your engine is affected, they will replace the cams, fuel pump and follower with updated parts as long as you are still under the warranty. If your car is affected, symptoms include a possible check engine light, fuel cuts, and loss of power.  Some dealers will not check until a check engine light appears.

The 2008 and up GTI has a revised engine known as the 2.0 TSI.  This engine uses a roller follower for the high pressure fuel pump and the issue is no longer a problem.

Cam follower information links:

Cam follower check

Maintenance Page

Troubleshooting